Integrated Plastic Waste Conversion Process

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Solution Overview

Problem

Existing thermochemical recycling processes for plastic and metal-containing waste require high energy intensity, auxiliary infrastructure, and external hydrogen gas, leading to greenhouse gas emissions and inefficiencies.

Innovation Solution

An integrated process utilizing a hydro-processing reactor coupled with a high-temperature aluminum water reactor generates hydrogen gas and thermal energy in situ, enabling thermochemical decomposition of mixed plastic and metal-containing waste without external hydrogen, and recovers valuable products like fuels and petrochemicals.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If external hydrogen gas is used for thermochemical decomposition, then the decomposition process can be carried out, but additional infrastructure and energy consumption are required

Engineering Contradiction:

Improvedecomposition process feasibilityVSAvoidauxiliary infrastructure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The system generates its own hydrogen gas internally through the reaction of aluminum waste with water, eliminating the need for external hydrogen supply infrastructure. The aluminum water reactor produces hydrogen that is directly utilized in the thermochemical decomposition process, making the system self-sufficient.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent combines the hydrogen production function and thermochemical decomposition function into an integrated system. The aluminum water reactor and thermochemical reactor are coupled such that hydrogen from the first reactor directly feeds into the second reactor, merging what would traditionally be separate processes.

Inventive Principle:

Principle #5Merging (Combining)

2Productivity

If high temperature pyrolysis is used to convert plastic waste, then liquid oils can be produced, but high energy intensity is required

Engineering Contradiction:

Improveliquid oil productionVSAvoidenergy intensity

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent changes the chemical parameters of the decomposition process by introducing hydrogen gas and water vapor into the thermochemical reactor. This modifies the reaction environment from simple thermal degradation to hydrogenation-hydrocracking-hydrothermal liquefaction, enabling lower temperature operation while maintaining liquid oil production.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Hydrogen gas acts as an intermediary substance that facilitates the decomposition process. Instead of relying solely on thermal energy, hydrogen serves as a chemical mediator that enables breakdown of plastic polymers at lower temperatures through hydrogenation reactions.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Power

If combustion of decomposition products is used for energy, then the decomposition process can be sustained, but greenhouse gas emissions increase

Engineering Contradiction:

Improveenergy for decompositionVSAvoidgreenhouse gas emissions

Core Design Contradiction:

PowerVSObject-generated harmful factors

Solution Approach 1:

The patent converts the typically harmful combustion process into a beneficial chemical reaction. Instead of burning decomposition products to generate energy (which produces CO2 emissions), the system uses aluminum waste reacting with water to generate hydrogen, which then drives the decomposition process without combustion.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent replaces the thermal combustion mechanism with a chemical reaction mechanism. Rather than using heat from burning hydrocarbons to drive the decomposition, the system uses chemical energy from aluminum-water reactions to generate hydrogen, which then chemically facilitates the decomposition process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If catalysts are used to improve pyrolysis efficiency, then process efficiency enhances, but additional materials and complexity are required

Engineering Contradiction:

Improveprocess efficiencyVSAvoidcatalyst infrastructure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The system uses the aluminum waste material itself as the catalytic agent. The aluminum reacts with water to generate hydrogen in situ, serving both as a reactant and as a catalyst for the decomposition process, eliminating the need for separate catalyst materials.

Inventive Principle:

Principle #25Self-service

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This process achieves high yield and efficiency in producing high-value products while reducing energy consumption and greenhouse gas emissions, with the ability to recycle metals and minimize coking, all without the need for external hydrogen gas.

Implementation Method 1

energy harnessed through an exothermic hydrogen production from metal-containing waste material feedstock

Methodology Applied

Scientific EffectExothermic reaction: Exothermic Reaction

Implementation Method 2

Pyrolysis, a common technique used to convert plastic materials into liquid oils, is the thermal degradation of plastic waste at different temperatures (300-900° C.), in the absence of oxygen

Methodology Applied

Scientific EffectPyrolysis: Pyrolysis